Short-time Pulse Based Electromagnetic Variable Blank Holding for High Efficiency Forming and Analysis of Energy Characteristics

doi:10.3901/JME.2025.23.203

Abstract

Abstract: Electromagnetic blank holding force offers greater loading flexibility and accuracy compared to traditional hydraulic cushions, and it also reduces the power requirement for forming equipment. Compared to traditional hydraulic cushions, electromagnetic blank holding offers significant advantages in the flexibility and precision control of the blank holding force curve, which can effectively reduce the installed power of the forming equipment. However, the continuous loading of current results in high energy consumption and overheating problems in electromagnetic blank-holding devices, presenting a significant challenge that requires attention in continuous forming. Therefore, a high-energy efficiency forming method for electromagnetic variable blank holding based on short-time pulse current is proposed. The electrical permanent magnet-driven variable blank holding forming system is designed, and feedback control is established for electromagnetic force loading under a short-time pulse current. According to the working point migration law in the magnet BH curve, the residual magnetic force after current unloading is used for variable blankholding. A model for electromagnetic force change and energy characterization under the action of pulse current is constructed to reveal the high-energy efficiency and low-energy consumption mechanism of the variable blank holding of short-time pulse current. A simulation model of electrical/magnetic/mechanical coupling is developed using Simulink-Simplorer-Maxwell. It is observed that the energy consumption during short-time pulse current loading, with the same variable electromagnetic force output, is only 9.87% of that during continuous current loading. The electromagnetic blank holding forming experiment conducted on the prototype of car doors demonstrates that the loading of variable blank holding force using short-time pulse current ensures forming quality while consuming only 14.03% of the energy compared to continuous current loading. Additionally, it reduces the tonnage requirement of hydraulic presses by 14%, which provides theoretical and methodological support for designing equipment to achieve low-tonnage, high-precision continuous forming of complex surfaces.

Key words: electromagnetic blank holding force, short-time pulse, high efficiency, forming

CLC Number:

TH139

LI Lei, HU Guozeng, XUAN Dengshi, HUANG Haihong. Short-time Pulse Based Electromagnetic Variable Blank Holding for High Efficiency Forming and Analysis of Energy Characteristics[J]. Journal of Mechanical Engineering, 2025, 61(23): 203-216.

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